Structural beams



June 27, 1961 H. DIAMOND 2,990,038

7 STRUCTURAL BEAMS Filed May 29,1959 :5 Sheets-Sheet 1 T AL-y- INVEN TOR. HARRY DIAMOND BY Sfiapim mu! SAapb-u A TTORNEYS June 27, 1961 H. DIAMOND 2,990,038

STRUCTURAL BEAMS Filed May 29, 1959 3 Sheets-Sheet 2 IN V EN TOR. HARRY DIAMOND E1 BY Sliqpim MS A TTORNEYS June 27, 1961 H. DIAMOND STRUCTURAL BEAMS 3 Sheets-Sheet 3 Filed May 29, 1959 INVENTOR. HARRY DIAMOND Sapirv and Sqairo HT E.ZL

5T5 Ell- ATTORNEYS United States Patent" 2,990,038 STRUCTURAL BEAMS Harry Diamond, P.0. Box 360, Elizabeth, NJ. Filed May 29, 1959, Ser. No. 817,441 4 Claims. (Cl. 189-37) This invention relates to structural beams, particularly to beams of the lightweight type from which certain portions of the web have been removed, and to methods of making the same. This application is a continuation-inpart of Serial No. 766,646, filed October 13, 1958, now abandoned.

As set forth in the aforesaid application, it is well lmown that beams over a certain length have a tendency to sag under their own weight. If such beams are used in floors or ceilings, the tendency to sag will upset the surface of the structure which the beams are supposed to support.

As further stated in the aforesaid application, it is well known that the resistance to stress depends to a great degree on the height of a beam. If an I beam of approximately 14 inches in height weighs about 17.2 pounds per foot, a similar beam 22 inches in height would deflect considerably less if it weighed the same. The 22 inch beam would normally weigh considerably more per foot than the 14 inch beam, however. It is an object of the invention to provide a beam having the advantages of the 22 inch beam but weighing less than the 14 inch beam.

' Broadly, it is an object of the invention to provide beams which are stronger per pound and lighter per foot of length for their height than comparable prior beams,

and which are more economical in production and use.

It is known that a beam may be converted to one of greater height by dividing the web of the beam longitudinally along a line of serration and then reuniting the divided parts by mating and joining the peaks of the serrations. The resultant beam has openings in its web,

which reduce the weight of the beam and which provide convenient passage for pipes, conduits, ducts, and wires. Such beams have not been economical to produce, however, because of the need for an intricate flame cutting operation, and they have not had the desired strength, because of the weakening eifects of the flame heat upon the metal. Moreover, the prior beams of this type have been heavier than necessary, and when welding has been employed to reunite the beam parts, an unduly large amount of welding has been necessary. Thus, even the availability of newer lightweight I beams suitable for conversion has not made the converted beams truly competi- 'tive with joists such as the truss type.

It is accordingly a primary object of the invention to provide a lightweight beam which overcomes the foregoing disadvantages.

Another object of the invention is to produce novel lightweight beams without flame cutting.

A further object of the invention is to produce lightweight beams by a conversion process which actually results in the workhardening of the final beam.

Still another object of the invention is to produce lightweight beams by unique cold-punching operations.

An additional object of the invention is to provide unique methods of making structural members.

A still further object of the invention is to provide a converted beam that is lighter in weight for its type than anything produced heretofore.

Another object of the invention is to provide improved methods of converting beams, in which material is actually removed from the beam webs.

An additional object of the invention is to provide unique processes in which beam parts are united by welding and in which the amount of welding required is minimized.

ice

Still another object of the invention is to provide novel structural members comprising beam parts having openings formed by cold-punching operations. 7

The foregoing and other objects, features, and advantages of the invention, and the manner in which the same are accomplished will become more readily apparent upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings, which illustrate preferred and exemplary embodiments, and wherein:

FIGURE 1 is an elevation view of an I beam to be converted in accordance with the invention;

FIGURE 2 is a transverse sectional view of the I beam taken along line 2-2 of FIGURE 1;

FIGURE 3 is an elevation view of the I beam after the performance of certain converting operations in accordance with one (form of the invention;

FIGURE 4 is an elevation view of the converted beam;

FIGURE 5 is a transverse sectional view taken along line 55 of FIGURE 4;

FIGURE 6 is a perspective view, somewhat diagrammatic, illustrating certain steps in another conversion method of the invention;

FIGURE 7 is a truncated elevation view of a beam after the performance of certain conversion steps;

FIGURE 8 is a perspective view, somewhat diagrammatic, illustrating the performance of additional conversion steps in accordance with the invention;

FIGURE 9 is a truncated elevation view of a beam on which additional conversion steps have been performed;

FIGURE 10 is a contracted elevation view of a partially converted beam illustrating the prospective removal of portions of the ends of the beam;

FIGURE 11 is a contracted elevation view illustrating a completely converted beam;

FIGURES 12 through 18, 20, 22, 24, and 26 are elevation views of different forms of structural members which may be made in accordance with the invention; and

FIGURES 19, 21, 23, 25, and 27 are end views of the forms illustrated in FIGURES 18, 20, 22, 24, and 26, respectively.

Briefly stated, the invention is concerned with the production of structural beams by dividing original beams longitudinally in such a way that the web is given a serrated edge. The serration process includes cold-punching operations which remove web material and workharden the serrated edge. The divided parts of the beam may then be staggered and reunited to form a beam of greater depth or may be assembled with other structural elements to form different types of members.

Referring to the drawings, FIGURES l-5 are taken from the aforesaid prior application. As set forth in that application, the I beam 10 of FIGURES l and 2 is convented by cold-punching out sections 11 therefrom along spaced elongated zones which extend diagonally across the longitudinal median line of the web 12 and which together define a zig-zag zone. The punching operations may be carried out on a hydraulic press, and the amount punched out may vary with the purpose for which the beam is to be employed. Successive sections 11 are oriented oppositely. The beam is sheared into two T sections 15 and 16 by shearing the web material between the adjacent ends of sections 11 along the lines 14. Thereupon the two sections are staggered longitudinally and are welded together at the sheared portions 14 to form welds 17. The converted beam designated 20 is considerably higher in depth than the original beam 10 and is provided with a series of openings 21, thus reducing the weight per foot considerably.

Because the converted beam is considerably lighter than 'versa, so that slots 42 and 48 become continuous. UREv 9 illustrates the beam after several of the slots 48 the original beam and considerably higher, it does not defleet'aymu'eh'as the original beam. Because of the strength of the welding and the additional height, the .conyerted bea m is stronger. Such a beam is more economical in building use, saving considerable money in the support of floors or. ceilings. .In addition to being lighter in weight the beam has a'better section modulus for equivalent spans.

advanced through the punch press in the direction of the arrow in a series of accurately spaced steps. Each time the carriage stops, the press cold-punches the beam, piercing the thickness of the web and removing a slug 48 so as to leave an elongated slot zone 42. The conveyor structure at the left of the punch press in FIGURE 6 may be part of a spacing table so that the intervals at which the slots 42 are produced may be accurately measured. As shown in FIGURE 7, the slots 42 have the general shape of a hockey stick with a leg portion 44 and a narrower foot portion 46. The leg portions are arranged diagonally and cross the longitudinal median line of the web. The foot portions are approximately parallel to the median line. In FIGURE 7 two of the slots 42 have been punched, and the next slot to be punched is shown in V phantom lines.

When a series of slots 42 has been punched along the length of the beam, .the carriage is reversed and the beam is moved back to the right side of the punch press. The beam is then turned over side-to-side so that the side of the web which previously faced upward faces downward. The beam is then moved through the punch press again in the direction of the arrow in a series of accurately spaced steps, and the cold-punching process is repeated, so that a second series of slots 48 is produced. During the punching of the second series, clamps are employed to held the beam together and maintain the proper flange spacing. The slots 48 alternate with the slots 42, being punched in the web material between them. The foot of each slot 48 joins the leg of the neXt slot '42 and vice FIG- have been punched, the next slot to be punched being shown in phantom lines.

The formation of the continuous slot divides the beam longitudinally into halves as shown in FIGURE 10. After the beam is divided longitudinally the portions spanned by the arrows 58, 60, and 62 are removed.

The slot formation gives a serrated edge to each of the beam parts 64 and 66 and produces interdigitated generally triangular projections and recesses. The projections have blunted tips 68 which lie adjacent the recess bottoms 70. It can be seen that the tips 68 are shorter in length than the recess bottoms 70 in the direction of the longitudinal axis of the beam.

' abutment, preferably on both sides of the web, so as to form a new beam 71 of greater height. Iig clamps may 'be employed to hold the halves of the beam in proper position during the welding. The converted beam may be provided with holes 74 in the Web for use in conjunction with rod-type bridging.

When the conversion of thebe-am is complete, the recesses of the opposed beam part edges form openings 72 in the web. Since the recess bottoms 70, which define part of these openings, are longer than the welded tips 68 as the result of the punching operations, the openings 72 are larger, and the amount of welding required along the blunted tips-68 is less than would be possible by flame cutting the beam along a line of serration; The removal of slugs by punching the beam also reduces the beam weight, as compared with flame cutting. Moreover, it has been discovered that while flame cutting of the web weakens the beam, cold-punching actually strengthens the converted beam by work-hardening the serrated edges.

FIGURE 12 illustrates a modified beam 76. The basic beam of FIG. 11 is bent into an arch after being formed in the manner previously described and is provided with end plates 78.

FIGURE 12 illustrates another structural member formed in accordance with the invention. The beam is similar to the beam of FIG. 11 but has angle members '82 Welded to its ends to support the beam on walls or girders. One of the beam halves forming this beam may have its ends shaped to a configuration different from that illustrated in FIGURE 10, so as to provide an overhanging web and flange portion at each end which is reinforced by the angles 82.

FIGURE 14 illustrates another structural member constructed in accordance with the invention. Here the beam 84 is like beam 71 but is provided with angle plates 86 on each side of the web at its ends for framing the beam to a girder.

In FIGURE 16 a beam in accordance with the inven tion is constructed from short sections 88 and 90 for ease in transporting the beam by air or pack animals. The sections may then be assembled by joining end plates 92 welded (to the beam.

FIGURES 15 and 17 illustrate modified forms of the invention, which employ one-half of the beam of FIG- URE 1.1. In these forms the beam half 94 or 96 is employed for reinforcing plates, decks, or hulls as indicated at 98 in FIGURE 15, are pipe lines such as 100 of FIG- URE 17. The beam elements may be fixed to the respective members 98 and 100 by Welding the serration tips thereto.

FIGURES 18-27 illustrate embodiments of the invention in which beam elements may be employed to form poles, stanchions, braces, shoring, or reinforcing, generally for use in upright position. As shown in FIGURES 18 and 19, a structural member 102 may be for-med by arranging several beam halves 104 so as to radiate from a central pipe 106 of circular cross-section. The blunted tips of the serrations may be welded to the external surface of the pipe.

In FIGURES 20 and 21, a structural member 108 is formed by arranging four beam halves 110 so as to radiate from a central pipe 112 of square cross-section, the blunted serration tips being welded thereto.

In FIGURES 22 and 23, a structural member 114 is formed by arranging four beam halves 116 radially and welding their serration tips directly together. FIGURES 24 and 25 illustrate a similar structural member 118 formed by three beam halves 120.

FIGURES 26 and 27 illustrate a decorative polygonal member 122 of triangular cross-section. Round, hexagonal, octagonal, flat, or other cross-sections are possible. In the embodiment shown, the beam halves 124 are formed from plate stock without flanges. The beam halves are united in pairs in the manner of FIGURE 11 and are then joined to similar elements to form the triangular member shown, as by welding along adjacent longitudinal edges.

It is apparent from the foregoing description of the invention that unique structural beams and methods of producing the same are provided. While preferred embodiments of-the invention have been shown and described, it will be appreciated by those skilled in the art that changes can be made without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims. Accordingly, the foregoing embodiments are to be considered illustrative, rather than restrictive of the invention, and those modifications which come within the meaning and range of equivalency of the claims are to be included therein.

The invention claimed is:

1. A structural beam and the like having a web with a series of openings therein spaced along the length of the web, the portions of the Web intermediate said openings having a longitudinal seam weld, the edges of the web surrounding said openings being substantially harder than the remainder of the web, said edges comprising longitudinal edge parts between edge parts which converge to meet said seam weld.

2. A structural member comprising a plurality of webs radiating from a common axis, each of said webs having a series of openings therein spaced along its length, the edges of the webs around said openings being harder than the remainder of the webs, the portions of each web intermediate said openings being connected to the corresponding portions of the other webs.

3. A structural beam and the like having a web with a series of openings therein spaced along the length of the web, the portions of the web intermediate said openings having a longitudinal seam, said web having edges surrounding said openings which converge to meet said than the remainder of the web.

4. The beam of claim 3, said edges having longitudinal edge portions between converging edge portions, said longitudinal edge portions being substantially longer than the length of said seam between successive openings.

References Cited in the file of this patent UNITED STATES PATENTS 334,567 Clemson Jan. 19, 1886 1,545,456 Rastetter July 7, 1925 1,644,940 Moyer Oct. 11, 1927 1,843,318 Frease Feb. 2, 1932 1,995,466 Bishop Mar. 26, 1935 2,002,044 Rothenstein May 21, 1935 2,641,829 Sasso June 16, 1953 2,662,272 Macomber Dec. 15, 1953 2,786,788 Anderson Mar. 26, 1957 FOREIGN PATENTS 706,311 France Mar. 30, 1931 900,943 France Oct. 23, 1944 UNITED STATES RATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,990,038 7 June 27, 1961 Harry Diamond It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent. should read as "corrected below.

Column 4, line l7 for "FIGURE 12" read FIGURE 13 line 40, for "are" read or column 6, line 2, after "said" insert longitudinal seam, said edges being substantially harder Signed and sealed this l lth-day of N0vember l96l.

(SEAL) Attest:

ERNEST W. SWIDER DAVID L. LADD Attesting Officer Commissioner of Patents USCOMM-DC- 

